Composite step brick

ABSTRACT

Present invention is related to a construction element made of a composite material which comprises at least one type of fiber and at least one type of resin. The construction element comprises a primary brick layer with a width of I1 and a secondary brick layer with a width of I2 that is narrower than I1 extending on the primary brick layer.

BACKGROUND OF THE INVENTION

Present invention is related to a construction element made of a composite material which comprises at least one type of fiber and at least one type of resin.

Today, constructions of living spaces are built with various bricks. In the past these bricks were made of clay and soil derivatives and they are still being used today. However, they are mostly superseded by gas concrete bricks today because they are heavy and don't provide good sound and heat insulation. Besides, bricks which are made of clay and soil derivatives, by their nature, get humid and reflect this humidity on the plaster from time to time. Due to their heavy structure, they also cause extra load on the beams and columns during construction and reduce the life of building. Gas concrete bricks keep the buildings cool in summers and hot in winters. But they are not preferred because they are more costly compared to other bricks. Besides, even though gas concrete bricks are more strong compared to the bricks made of clay and soil derivatives, their mechanical strength is not so high. When building a wall with bricks made of gas concrete, bricks should be cut or broken into pieces in the corner joints etc. Due to this reason, a need for extra labor rises during construction.

Heat resistance of composite bricks is quite high due to their composite structure. They are safe against fire or burning in similar events that may occur either from outside or inside thanks to their composite structure. Heat insulation feature of composite material prevents transition of hot air in summers and cold air in winters. Composite bricks are also very light and extend the life of buildings by preventing overload on beams and columns. Composite bricks can be placed one on top of another or side by side constituting a solid structure by connecting to composite connectors. Said composite bricks are quite resistant to corrosion occurring in time and mechanical strengths.

Composite bricks are subject to the useful model with the application number 2010/02169; however, singly use of composite bricks increases labor.

As a consequence, all the above mentioned problems created the need to make an improvement in the relevant technical field.

BRIEF DESCRIPTION OF THE INVENTION

The present invention is related to a new composite step brick, aimed at eliminating the abovementioned disadvantages and bringing new advantages to the relevant technical field.

Main object of the invention is to provide a step brick which doesn't involve labor and application difficulty, and enables a serial building production compared to other construction materials.

Another object of the invention is to provide a step brick which reduces the cost of buildings and is superior to other construction materials in terms of insulation and lightness.

In order to perform all of the abovementioned objects and the objects which are to be deducted from the detailed description below, the present invention is a construction element made of a composite material which comprises at least one type of fiber and at least one type of resin. According to this, said construction element is characterized by comprising a primary brick layer with a width of I1 and a secondary brick layer with a width of I2 that is narrower than I1 extending on the primary brick layer.

In a preferred embodiment of the subject matter invention, difference between the I1 width of primary brick layer and I2 width of secondary brick layer is equally distributed on two sides of the secondary brick layer.

In another preferred embodiment of the subject matter invention, it comprises at least one connection channel which connects one lateral surface of construction element to the lateral surface of another construction element, and at least one connection protrusion which is inserted into said connection channel.

In another preferred embodiment of the subject matter invention, construction element is a male step brick which comprises multiple connection protrusions on its surface facing the other construction element.

In another preferred embodiment of the subject matter invention, construction element is a female step brick which comprises multiple inserts on its surface facing the other construction element.

In another preferred embodiment of the subject matter invention, step brick comprises at least two pieces of step bricks that connect to each other, and at least one insert and at least one connector which enable connection of said pieces of step bricks to each other.

In another preferred embodiment of the subject matter invention, secondary brick layer comprises at least one brick layer on it which is narrower than the brick layer under it.

In another preferred embodiment of the subject matter invention, it is made of a composite material which comprises at least one type of fiber at a ratio of 25-33% in order to provide strength, at least one type of mineral powder as a filler at a ratio of 40-50%, at least one type of resin at a ratio of 20-25% as the item bonding the fiber with filler and at least one chemical additive at a ratio of 5-8%.

In another preferred embodiment of the subject matter invention, it comprises vinyl ester resin as the resin and carbon-fiber as the fiber in order to possess mechanical properties of the ST 50 steel and above.

In another preferred embodiment of the subject matter invention, it comprises middle phthalic resin as the resin and glass-fiber as the fiber in order to possess mechanical properties of steels between ST 33 and ST 42.

In another preferred embodiment of the subject matter invention, it comprises izophthalic resin as the resin and aramid-fiber as the fiber in order to possess mechanical properties of steels between ST 42 and ST 50.

In another preferred embodiment of the subject matter invention, it comprises at least one type of mineral powder as filler, selected from a mineral group which comprises silica, barite, talcum and calcite.

In another preferred embodiment of the subject matter invention, as a chemical additive, it comprises at least one of the chemicals which increase water absorption and resistance to flame and abrasion, and optionally, thermoplastic material at a pre-specified ratio so as to enhance the surface appearance.

BRIEF DESCRIPTION OF THE FIGURES

In FIG. 1 a, a general view of a step brick that is part of the male step brick is given.

In FIG. 1 b, a general view of male step brick is given.

In FIG. 2 a, a general view of a step brick that is part of the female step brick is given.

In FIG. 2 b, a general view of female step brick is given.

In FIG. 3, a sample construction made of step bricks is given.

REFERENCE NUMBERS GIVEN IN FIGURES

-   10 Male step brick -   11 Step brick piece -   111 Insert -   121 Primary brick layer -   122 Secondary brick layer -   123 Tertiary brick layer -   124 Quaternary brick layer -   13 Lateral surface -   131 Connection channel -   132 Connection protrusion -   14 Connection extension -   141 Clearance -   20 Female step brick -   21 Step brick piece -   22 Insert -   30 Construction -   I1: Width -   I2: Width -   I3: Width -   I4: Width

DETAILED DESCRIPTION OF THE INVENTION

In this detailed description, the subject matter invention is explained with references to examples without forming any restrictive effect in order to make the subject more understandable.

Referring to FIGS. 1 a and 1 d; subject invention male step brick (10) with composite structure consists of two identical step brick pieces (11) connected to each other via a connector (not shown in the figure) at their opposite inserts (111). Male step brick (10) has connection extensions (14) which are provided one after each other horizontally with a space in-between and extend upwards. Connection extension (14) has a hollow box like shape so that it defines a clearance (141).

Referring to FIGS. 2 a and 2 b, a female step brick (20) also consists of two composite step brick pieces (21) connected to each other and has inserts (22) provided one after each other horizontally so as to connect to the connection extensions (14) of male step brick (10).

Step brick pieces (11, 21) are symmetrical widthwise dimidiate forms of step bricks (10, 20). Step bricks (10, 20) consist of a primary brick layer (121) and a secondary brick layer (122), a tertiary brick layer (123) a quaternary brick layer (124) on said primary brick layer (121), respectively. Width of said brick layers (121, 122, 123, 124) is I1, I2, I3 and I4 respectively. I1 width of primary brick layer (121) which is at the lowest layer of step brick (10, 20) is the widest and 14 width of quaternary brick (124) which is at the top is the narrowest. Male step brick (10) includes inserts (22) at the lower part of primary brick layer (121); female step brick (20) comprises connection extensions (14) at the primary brick layer (12).

In a preferred embodiment of the invention, male step brick (10) has lateral surfaces (13) and there are connection channels (131) and connection protrusions (132) that are opposite to each other on said lateral surfaces (13).

In FIG. 3, a sample construction (30) is shown and according to this, step bricks (10, 20) connect to each other like toy blocks. Connection protrusions (22) match with the inserts (22). While laying the composite bricks (10, 20), a space is formed between two male step bricks (10) or two female step bricks (20) that are placed on the ground side by side, suitable for a composite step brick (10, 20) to be placed as rotated for 180 degrees. Female step brick (20) or male step brick (10) is placed into said space according to the form of step bricks (10, 20) laid side by side. Connection between connection channels (131) and connection protrusions (132) of the lateral surfaces (13) increase stability.

Composite step brick (10, 20) is produced in the desired form by a press at a time and their construction is more rapid compared to the construction of composite individual bricks that connect to each other. And this leads to a decrease in labor. Step bricks (10, 20) can be produced with various dimensions and forms, and large sized step bricks (10, 20) are used for large areas whereas small sized step bricks (10, 20) are used or a single brick satisfies the need for small areas. Thus, desired constructions are built by decreasing labor.

Composite step bricks (10, 20) are made of a material based on SMC (sheet molding composites) and they are produced through a known production method in this field. According to this, in a preferred formulation, subject composite material comprises fiber at a ratio of 25-33% in order to provide strength, at least one type of mineral powder as a filler at a ratio of 40-50%, resin at a ratio of 20-25% as the item bonding the fiber with filler and at least one chemical additive at a ratio of 5-8%. In order to obtain a material which has a relatively high strength and values of ST steel, vinyl ester resin is preferred as the resin and carbon-fiber is preferred as the fiber. In the parts which don't require high strength, so as to obtain a material which has relatively low strength and possesses the values of ST 37 steel in particular, isophtalic resin is preferred as the resin and glass-fiber is preferred as the fiber. In the construction elements which require middle strength, isophtalic resin is preferred as the resin and aramid-fiber is preferred as the fiber, in order to obtain a material with the values of ST 42 steel. Wall thickness of the subject invention composite step bricks (10, 20) can preferably be between 4 mm and 2 cm depending on the desired strength.

On the other hand, at least one type of mineral powder selected from a mineral group which comprises silica, barite, talcum and calcite is used as filler and at least one of the chemicals which increase water absorption and resistance to flame and abrasion is used as a chemical additive. In addition to these, subject formulation may also comprise thermoplastic material at a pre-specified ratio so as to enhance the surface appearance.

Besides, construction elements aren't composed of multiple layers which have different physical and chemical properties as it was in the prior art, and this allows the construction elements and buildings constructed with these elements to possess the required rigidity and durability. Ease and speed of production gained by this way provides a significant advantage.

Some of the test data of a construction element subject to invention, which is produced through a sample formulation, is as below.

Tests Test Method Values Determination of TS 985 ≧160 Flexural EN ISO 178 Strength (N/mm²) Determination of EN ISO 527-4 ≧222 Tensile Strength (MPa) Impact Strength EN ISO 179 ≧110 (kj/m²) Barcol Hardness EN59 70 Water absorption (%) TS 702, ISO 62 Max 0.15% in 24 hours % 0.15 Density (gr/cm³) TS 1818, 1.79 ASTM D792 Chemical Resistance EN ISO 14125 Change in weight; (60% toluene, 40% max. %0.5 n-heptane in volume Change in bending resistance; or in diesel, under −20% the conditions of 23 ± Change in bending 2° C. and 168 ± hours) module; −30% (TS 1478 EN 124 Annex E) Surface Resistance DIN IEC 93 5 × 10⁹  (Ω) Volume Resistance (Ω) DIN IEC 93 5 × 10¹⁰ Specific DIN IEC 93 1 × 10¹² Transresistance (Ω.cm) Ball Pressure Test Ball Diameter max. 2 mm. Glow Wire Test No Dropping Accelerated Heat No puncture or deformation Damping Test Isolation Test No discharge or deformation Temperature Changes No deformation or crack Resistance Test Ultra Violet No deformation or crack Resistance Test

The protection scope of the present invention is set forth in the annexed claims and cannot be restricted to the illustrative disclosures given above, under the detailed description. It is because a person skilled in the relevant art can obviously produce similar embodiments under the light of the foregoing disclosures, without departing from the main principles of the present invention. 

1. A construction element comprising: a primary brick layer having a width of I1; and a secondary brick layer having a width of I2 that is narrower than I1 extending on the primary brick layer ; wherein the primary brick layer and the secondary brick layer comprise a composite material comprising at least one type of fiber and at least one type of resin.
 2. A construction element according to claim 1, wherein the difference between the I1 width of primary brick layer and I2 width of secondary brick layer is equally distributed on two sides of the secondary brick layer.
 3. A construction element according to claim 1, comprising at least one connection channel which connects one lateral surface of construction element to the lateral surface of another construction element, and at least one connection protrusion which is inserted into said connection channel.
 4. A construction element according to claim 1, wherein the construction element is a male step brick which comprises multiple connection protrusions on its surface facing the other construction element.
 5. A construction element according to claim 1, wherein the construction element is a female step brick which comprises multiple inserts on its surface facing the other construction element.
 6. A construction element according to claim 4, wherein the step brick comprises at least two pieces of step bricks that connect to each other, and at least one insert and at least one connector which enable connection of said pieces of step bricks to each other.
 7. A construction element according to claim 1, wherein the secondary brick layer (122) comprises at least one brick layer on it which is narrower than the brick layer under it.
 8. A construction element according to claim 1, wherein the composite material comprises at least one type of fiber at a ratio of 25-33% in order to provide strength, at least one type of mineral powder as a filler at a ratio of 40-50%, at least one type of resin at a ratio of 20-25% as the item bonding the fiber with filler and at least one chemical additive at a ratio of 5-8%.
 9. A construction element according to claim 4, further comprising vinyl ester resin as the resin and carbon-fiber as the fiber in order to possess mechanical properties of the ST 50 steel and above.
 10. A construction element according to claim 4, further comprising middle phthalic resin as the resin and glass-fiber as the fiber in order to possess mechanical properties of steels between ST 33 and ST
 42. 11. A construction element according to claim 4, further comprising izophthalic resin as the resin and aramid-fiber as the fiber in order to possess mechanical properties of steels between ST 42 and ST
 50. 12. A construction element according to claim 4, further comprising at least one type of mineral powder as filler, selected from a mineral group which comprises silica, barite, talcum and calcite.
 13. A construction element according to claim 4, further comprising a chemical additive, comprising at least one of the chemicals which increase water absorption and resistance to flame and abrasion, and optionally, thermoplastic material at a pre-specified ratio so as to enhance the surface appearance. 